Foam-fillable enclosure

Abstract

An enclosure for having foam generated and contained therein is defined between two layers of flexible thermoplastic material, which are edge sealed to define an enclosed unit. One inwardly facing surface of one layer is coated with a first foam generating agent, such as crystals, and the opposite, inwardly facing surface of the other layer is coated with capsules of another foam forming agent, wherein the capsules prevent mixing of the two agents for generating foam. Upon subsequent rupture of the capsules, the foam generating agents mix, react and generate foam in the enclosure. An additional layer may be disposed between the two exterior layers. Both surfaces of the additional layer also carry one of the foam forming agents, whereby two enclosures are defined, one over the other, each for generating and containing foam. In forming the enclosed unit, each layer is separately coated with its respective foam forming agent and thereafter the layers are secured together to define the enclosure.

What is claimed is: 
     
       1. An enclosed unit for defining an enclosure for generation and containment of foam therein, comprising; a first and a second layer of flexible material for containing generated foam and foam forming agents; the first and second layers being joined together for defining an enclosure between them; the first and second layers having respective first and second opposite surfaces which face toward each other and into the enclosure;   a first foam forming agent coated on and supported on the first surface; a second foam forming agent coated on and supported on the second surface; the first and second agents being such that upon mixing together of the agents, they generate foam in the enclosure between the first and second surfaces;   at least one of the foam forming agents being encapsulated in rupturable capsules comprised of a material which contains the agent, the capsules being for preventing mixing of the first and second agents, the capsules being adapted to be ruptured for releasing the agent encapsulated, whereby upon capsule rupture the agents come into contact and coact to generate foam in the enclosure.   
     
     
       2. The unit of claim 1, wherein the layers are comprised of a thermoplastic material. 
     
     
       3. The unit of claim 1, wherein at least one of the first and second layers is at the exterior of the unit. 
     
     
       4. The unit of claim 3, wherein both of the first and second layers are at the exterior of the unit at opposite sides of the unit. 
     
     
       5. The unit of claim 4, wherein the unit comprises at least one additional layer between the exterior layers; the additional layer having a third surface facing and being opposite one of the first and second surfaces and a foam-forming agent being coated on the third surface and that agent being selected to generate foam when mixed with the agent on the respective one of the first and second surfaces to which the third surface faces; whereby an enclosure is defined between the third surface and the surfaces it faces. 
     
     
       6. The unit of claim 5, wherein the additional layer has a respective one of the third surfaces at both of its opposite surfaces, whereby a respective enclosure is defined above both opposite surfaces of the additional layer. 
     
     
       7. The unit of claim 1, wherein the layers are overlaid and have respective marginal edges which are secured together for defining the edges of the enclosure and for enclosing the enclosure. 
     
     
       8. The unit of claim 7, wherein the layers are comprised of a thermoplastic material. 
     
     
       9. The unit of claim 1, wherein the layers are comprised of a non-stretchable material. 
     
     
       10. The unit of claim 9, wherein the layers are comprised of a thermoplastic material. 
     
     
       11. The unit of claim 1, further comprising a plurality of posts in the enclosure and extending between the opposite first and second surfaces for spacing apart those opposite surfaces. 
     
     
       12. The unit of claim 11, wherein the posts are defined in one of the first and second surfaces and are attached to the other of the first and second surfaces. 
     
     
       13. The unit of claim 1, wherein one of the agents comprises crystals of toluene di-isocyanate and the other agent comprises water in capsules, the capsules being of a material which does not react with toluene di-isocyanate. 
     
     
       14. An enclosed unit for defining an enclosure for generation and containment of foam therein, comprising; a first and a second layer of flexible material for containing generated foam and foam forming agents; the first and second layers being formed together for defining an enclosure between them; the first and second layers having respective first and second opposite surfaces which face toward each other and into the enclosure;   a first foam forming agent coated on and supported on the first surface; a second foam forming agent coated on and supported on the second surface; the first and second agents being such that upon mixing together of the agents, they generate foam in the enclosure between the first and second surfaces;   at least one of the agents being supported on its respective surface with means which prevent mixing of the one agent with the other agent, and that means being adapted for being operated upon to release the one agent to mix with the other agent, whereby upon such operation upon that means, the agents come into contact and coact to generate foam in the enclosure.   
     
     
       15. A method of forming a unit to define an enclosure for generation and containment of foam therein, the method comprising: coating a first foaming agent on one inwardly facing surface of a first layer comprised of a flexible material which defines the enclosure;   coating a second foam-forming agent on a second inwardly facing surface of a second layer of a flexible material which defines the enclosure, wherein the first and second surfaces face each other and are opposite each other;   wherein at least one of the agents is encapsulated in rupturable capsules comprised of a material which contains the one agent and which material does not react with the other agent, and the capsules are for preventing mixing of the first and second agents, the capsules being adapted to be ruptured for releasing the agent encapsulated, whereby upon capsule rupture, the agents come into contact and react to generate foam in the enclosure.   
     
     
       16. The method of claim 15, wherein the first and second layers are initially separate and their coated surfaces are respectively coated while the layers are separate; after coating of the first and second surfaces of the layers, securing the layers together with the coated surfaces facing each other opposite each other and overlaid. 
     
     
       17. The method of claim 15, wherein the agents are coated on their respective surfaces by adhering them to those surfaces. 
     
     
       18. The method of claim 15, including a third one of the layers located outside the second agent and the foam-filled enclosure is defined between the first and second layers. 
     
     
       19. The method of claim 18, further comprising coating the third surface of the second layer on the opposite side of the second layer, with one of the first and second agents and coating the inwardly facing fourth surface of the third layer, which is opposite and faces toward the third layer, with the other of the first and second agents. 
     
     
       20. A method for producing a foam-filled enclosure, comprising forming the unit according to claim 15, and thereafter rupturing the capsules for freeing the one agent to contact the other agent for generating foam in the enclosure.